Professional Documents
Culture Documents
Laboratory
Report
Abstract
In this experiment, lead billets (which were in the warm working states because of its soft
metal characteristics) were extruded with the observed variables being extrusion
direction, die geometry, and use of lubrication. The objectives of the experiment
included determining the significance of each variable in the extrusion process, both
individually and in combination with each other. In addition, the presence of dead metal
zones and piping were examined. Eight trials were run with each combination of the
variables, and data of the force required and displacement during extrusion was captured
using a dynamometer and LVDT connected to a data acquisition computer. Two level
factorials, a cube plot, and a probability curve were used to determine significance of the
effects. From our data analysis, it was determined that using a reverse extrusion process
will require less force than a comparable direct extrusion process, due to less friction of
the billet in the chamber. A square die, which reduces the surface area compared to
rounded dies, will also reduce the break through force required for the extrusion.
Lubrication reduces overall friction and therefore reduces the force necessary for the
extrusion process, although a greater change in force is observed when using lubrication
with direct extrusion. The use of a square die will generally result in larger dead metal
zones, and piping will also occur when the extrusion uses a square die. Piping and dead
metal zones are usually dependant upon die geometry, but independent of the direction of
extrusion.
Table of Contents
Title Page
Abstract
Table of Contents
Equipment Used
Analysis
Conclusions
Appendix
1
2
3
4
6
15
16
Equipment Used
Prior to the extrusion itself, red layout dye was painted on the inside split of the billets
and a height gauge was used to scratch lines every 0.100 inches both along the axis of the
split billets, and perpendicular to the axis. This would allow a visualization of the flow
characteristics after the extrusion.
Two different extrusion dies were used in the experiment, one was a direct extruder, and
the other was a reverse extruder. The direct extrusion die stays stationary while the force
is applied, while in the reverse extrusion process, the force is applied to the die, which
applies pressure to the billet to form the extrusion, as seen in Figure 1 below.
Die
(square)
Die
(square)
F
F
F
Direct Extrusion
Reverse Extrusion
CHARGE [pC]
AMP
A/D CONVERTER
[V]
[V]
IN COMPUTER
ORDINARY
[digital
AMP
signal]
[mV]
Analysis
S.O. #1 (Forward, Square, No Lube)
10000
9000
8000
7000
6000
Force
(lbs)
5000
4000
3000
2000
1000
0
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
Displacement (in.)
1.
of the decrease of the force, rather than a constant force, is that the
reduction of the length of the billet in the chamber (as the test
proceeds) reduces the friction, and therefore, the overall force
decreases as the displacement increases (until Area III). The horizontal
line at approximately 7100 lbf represents the separation of force due to
deformation and friction. The force below the line represents the force
due to deformation and the area above the line represents force due to
friction. When doing indirect extrusion, the area above line is greatly
reduced (See Appendix for other charts).
At Area III, the force required for displacement once again increases.
This is due to the small amount of billet left in the chamber. The vast
majority of the billet has already been extruded, leaving only the dead
metal zone in the chamber. The force required to compress this dead
metal zone is quite high due to its already compact state, and the sharp
angle it would need to take to leave the chamber with the extrusion.
The extrusion is usually stopped at or before Area III because the
majority of extrusion has been completed and the remaining extruded
part that is comes out in Area III usually has imperfections in its
structure.
There is usually a region before Area I in which the slope of the curve
is less than the slope of Area I. The above graph does not illustrate
this, but most of the graphs in the appendix do. This region is
associated with the billet taking shape of the chamber and the air being
pushed out.
Using the breakthrough forces of the eight trials, the contrasts and effects could be found.
A sample calculation of the contrast and effect can be found in the appendix.
Figure 4. Effects Statistical Table
2.
From the probability plot (See Appendix), it can be seen that the direction (D),
geometry (G), lubrication (L), interaction of direction and lubrication (DL) are
significant. This is known because their respective effects are outside of the 95%
range on the probability plot, which corresponds to 400. Those numbers that lie
between plus and minus 400 are not considered significant for our experiment.
Using reverse extrusion, rather than direct (forward) extrusion, will require an
average of 1397 lbf less of force than using the direct extrusion technique. The
reason for this is the difference in the process fundamentals of the two techniques.
When direct extrusion is used, the entire surface area of the billet is always moving
against the walls of the chamber. When identical settings are used for indirect
extrusion, it can be seen that the billet does not move along the chamber wall, but on
the portion of the billet moving through the die is experiencing friction with the die or
chamber. Moreover, it is not just that the surface area of the billet is touching the
walls of the chamber and moving with respect to them, but when an immense force
(several thousand pounds) is pushing against the billet to extrude it, some of this force
is transferred to a force pushing out against the walls, further increasing the friction
force.
When geometry is considered, it can be seen that when a rounded rather than square
die is used, the required force is on average 483 lbf higher. This may not seem logical
at first glance, as a rounded die is smoother and would seem to cause less friction.
However, the main factor to consider
when comparing the geometry is the
surface area of the die. A square die
has linear walls; a rounded die has
Square die
linear walls for most of the length,
but curves out near the end,
increasing surface area, as seen in
Round die more
Figure 5. More surface area leads to
surface area
more friction, and therefore higher
required forces for extrusion.
Figure 5 Die Geometry
Lubrication was the most significant factor in this experiment, which was evident
especially when looking at the break through force of forward extrusion. When using
lubrication, there was an average of 1004 lbf less force needed. This correlation is
fairly obvious. If lubrication is added to the exterior of the billet prior to extrusion,
friction between the billet and the die and walls will be reduced, and therefore less
force will be needed to extrude the metal.
The interaction of extrusion direction and the use of lubrication were also significant.
This is logical, as the two were both quite significant as independent main effects.
Since the billet does not move in the indirect extrusion process, the frictional forces
on the wall do not need to be overcome. However, when we did use lubrication during
the reverse extrusion, we did see a reduction of 303 lbf in break trough force. Since
lubrication was added to the outside of the billet, and force was applied to the billet
by the die, the only place the lubrication could leave the chamber was through the die.
The break through force was less but not nearly as significant as it was in direct
extrusion. When we used lubrication on forward extrusion, the required forces were
1705 lbf less than without using lubrication. The use of lubrication has a greater effect
on the direct extrusion process because the frictional force caused by the billet
pressing against the chamber wall is greatly reduced.
4.
8213
8140
9956
8398
Breakthrough
Force (lbf)
G
L +
9312
7646
7729
8076
Figure 6. Cube Plot of Effects
Table 1- Break Through Forces
S.O.1
Break Through Force
(lbs)Lab Estimates
9312
S.O.2
8076
S.O.3
9956
S.O.4
8398
S.O.5
7646
S.O.6
7729
S.O.7
8213
S.O.8
8140
5.
S.O.1
1
Forward
S.O.2
S.O.3
2
3
Reverse Forward
S.O.4
4
Reverse
S.O.5
5
Forward
S.O.6
6
Reverse
S.O.7
7
Forward
S.O.8
8
Reverse
Square
NO
Square
NO
Round
NO
Square
YES
Square
YES
Round
YES
Round
YES
Round
NO
6.
The dead metal zones are located next to the die, but on the outside edge of the
chamber (See Figure 8). From Table 2, it can be seen that generally the square dies will
produce larger dead metal zones. Samples 1 and 5 all had large dead metal zones, and
samples 2 and 6 had moderate side dead metal zones. All of these samples used square
dies. This agrees with the theory and mechanics of the die. For metal along the outer
edge of the chamber, it has to make its way to the center of the chamber, and then make a
90 degree turn to be extruded. This is difficult to do, so a dead metal zone results. For
rounded dies, the metal along the wall of the chamber has a smoother path to be extruded
(no sharp bends), so usually minimal or no dead metal zones result. When using a round
die and a forward extrusion process, frictional forces are present between the billet and
the chamber wall, so it is harder for the material on the outside of the billet to make it
through the die. Dead metal zones were present in this extrusion, but not to the extent
when using a square die.
lead to more piping in the samples (which agrees with the presented results), as the sharp
angle needed to be taken by the metal to be extruded will cause the far edge of the billet
to be pulled toward the center. At this point it is easier for the center of the top of the
billet to move in the direction of the extruded portion (causing piping) than for the
outside of the billet to translate to the center of the chamber and make a sharp turn
forming the extruded portion. The rounded die did not form piping because a smoother
path can be taken to the exit of the die (it is easier for metal near the outside of the billet
to move to form the extruded portion, even though there is more friction with the
increased surface area of the rounded die).
Conclusion
By looking at breakthrough forces of the trials, several conclusions can be drawn. Using
a reverse extrusion process will require less force than a comparable direct extrusion
process, due to less friction of the billet in the chamber. Square dies reduce the surface
area versus rounded dies, and therefore also reduce the force required for extrusion.
Lubrication reduces overall friction and therefore reduces the force necessary for the
extrusion process. The use of a square die will generally result in larger dead metal
zones, and piping will occur when extrusion is done with a square die.
One possible source of error in this experiment is the fact that the tensile test machine
may not have been operated in exactly the same manner for all specimens. The knob was
supposed to be placed at a scratch representing 3.5 on the machine, but some groups may
have been slightly higher or lower, resulting in faster or slower extrusion, which will
affect the strain rate of the lead. We also saw metal extruded between the chamber wall
and the ram, which would lead to a lower recorded break through force than actual.
Suggestion for future labs would be to combine the data from all of the labs so that there
is more data. The analysis of one sections data is not enough to fully conclude what
should be correct. If one group in our section did the extrusion wrong (e.g. had the dial at
4.5 instead of 3.5), the data for our section would be incorrect but since we only have a
sample size of 1, we have to assume that is correct. The sample sizes of each extrusion
process should be larger.
The operator should have less control over the process. The dial should be automated and
should only have to press one button to start the test. By having a manual dial, and the
process of pushing two buttons at once, there are at least two more variables being added
to each extrusion. Since we had 8 different samples, there were most likely 8 different
operators, which means 8 more variables and possible sources of error. However, we
assumed that none of these variable existed, which is not entirely correct, and could have
led to inaccurate data by fault of no one.
Appendix
Sample Calculations:
Contrast of D:
(-9312+8076-9956+8398-7646+7729-8213+8140) = -2784
Effects of D:
N= 8 (number of Samples)
(Contrast of D)/(N/2) = -696/(8/2) = -696
P(i)= 100*(i-.5)/N
i = ascending order number associated with each effect (lowest to highest)
Order
L
D
DG
GL
DGL
G
DL
Effects
Value
-1003.5
-696
-119.5
3
41.5
486
701
P(I)
7.14
21.43
35.71
50
64.29
78.6
92.86